Sealing High Pressure Flow Devices

ABSTRACT

Apparatus and method contemplating a high pressure flow device having a body defining a body bore and defining a recess in the body intersecting the body bore. A closure is joined to the body and forms a sealing surface. A seal is mounted to the body in the recess and configured to extend from the recess beyond the body bore to seal against the sealing surface formed by the closure.

BACKGROUND

This technology relates generally to sealing fluid flow passages inside flow control devices, such as those particularly suited for use in high pressure oil and gas production and processing systems.

One such type of flow control device is a valve. Generally, a valve forms a flow passage and has a selectively operable closure to open or close the flow passage in order to control a flow of fluid through the valve. The sealing integrity of high pressure valves must withstand not only high operating fluid pressures, presently 15,000 pounds per square inch and higher, but also must do so while controlling the flow of corrosive and/or abrasive fluids that are notorious for eroding the valve internal components in the oil and gas industry.

Illustrative embodiments herein are directed to a plug valve although the contemplated embodiments are not so limited. In a plug valve the flow passage typically includes a valve body in fluid communication with two or more openings, typically an inlet opening and an outlet opening, forming a flow passage through the valve body. A valve plug and insert segments, one type of a valve closure that is described herein, are disposed in a valve body bore between the inlet and outlet openings where sealing occurs between the plug, the insert, and the bore. The valve plug defines a through-opening and is selectively rotatable to an open position where the through-opening is aligned with the flow passage to permit a flow of fluid through the valve (from the inlet to the outlet), or to a closed position where the through-opening is misaligned with the flow passage to prevent the flow of fluid through the valve. Operating a valve in the harsh oilfield conditions can cause erosion of the valve body bore where the seal in the insert abrades against the bore, often resulting in leakage in a short amount of time. Repairing the valve body, such as by a weld build-up and machining operation, is a cumbersome and disruptive repair in the oilfield.

The illustrative embodiments of this technology directed to plug valves are in no way limiting of the contemplated embodiments of this technology. The skilled artisan understands that in alternative embodiments this technology can be used in other types of valves having differently configured closures. However, an enumeration of all the different types of valves that are suited for using this technology is not necessary for the skilled artisan to understand the scope of the claimed subject matter, so no such enumeration is warranted.

Improvements are needed in the internal sealing of high pressure flow devices to increase operating life while reducing downtime and operating cost. What is needed is a solution that transfers the erosion (corrosion and abrasion) from the high pressure fluid device body to the component sealed with the body. It is to those improvements that embodiments of this technology are directed as described in the illustrative embodiments and contemplated within the scope of the claims.

SUMMARY

Some embodiments of this technology contemplate a high pressure flow device having a body defining a body bore and defining a recess in the body intersecting the body bore. A closure is joined to the body and forms a sealing surface. A seal is mounted to the body in the recess and configured to extend from the recess beyond the body bore to seal against the sealing surface formed by the closure.

Some embodiments of this technology contemplate a valve having a valve body defining a valve body bore and defining a recess intersecting the valve body bore. A flow passage is formed through the valve body. A valve plug has a journal supported by the valve body permitting selective rotation of the valve plug in the flow passage. A valve insert is disposed between the valve plug and the valve body. A seal is mounted to the valve body in the recess and is configured to extend from the recess beyond the valve body bore to seal against a sealing surface formed by the valve insert.

Some embodiments of this technology contemplate a fluid flow apparatus having a body defining a flow passage, a closure mounted to the body in the flow passage, and means for sealing between the body and the closure.

Some embodiments of this technology contemplate a plug valve having a valve body defining a valve body bore and a seal mounted to the valve body adjacent the valve body bore. A valve plug is supported by the valve body and a valve insert is disposed between the valve plug and the valve body bore defining a sealing surface for the seal.

BRIEF DESCRIPTION OF THE DRAWINGS

Details of various embodiments of the present technology are described in connection with the accompanying drawings that bear similar reference numerals.

FIG. 1 is a cross-sectional depiction of a plug valve that is constructed in accordance with previously attempted solutions.

FIG. 2 is a cross-sectional depiction of another plug valve that is constructed in accordance with other previously attempted solutions.

FIG. 3 depicts enlarged portions of the plug valve in FIG. 1.

FIG. 4 depicts enlarged portions similar to FIG. 3 but of a plug valve that is constructed in accordance with embodiments of this technology.

FIG. 5 depicts more of the plug valve of FIG. 4.

FIG. 6 is a cross-sectional depiction of another plug valve that is constructed in accordance with this technology.

FIG. 7 is an isometric depiction of a valve insert in the plug valve depicted in FIG. 1.

FIG. 8 is similar to FIG. 7 but depicting a different cross-section through the plug valve.

DETAILED DESCRIPTION

Initially, this disclosure is by way of example only, not by limitation. The illustrative constructions and associated methods disclosed herein are not limited to use or application for sealing any specific assembly or in any specific environment. That is, the disclosed technology is not limited to use in sealing valves and fluid ends as described in the illustrative embodiments. Thus, although the instrumentalities described herein are for the convenience of explanation, shown and described with respect to exemplary embodiments, the skilled artisan understands that the principles herein may be applied equally in sealing other types of high pressure flow devices.

FIG. 1 is a cross-sectional depiction of a plug valve 100 that is constructed according to previously attempted solutions. The plug valve 100 has a forged valve body 102 forming a tapered internal bore 104. Inserts 106 a, 106 b in these illustrative embodiments are segments of an open hollow cone. Although two inserts 106 a, 106 b are depicted, the contemplated embodiments are not so limited because alternatively there can be more than two. Each insert 106 a, 106 b has an outer conical surface 108 a, 108 b forming a matching taper to engage against the bore 104 in a close mating relationship.

A cylindrical plug no has an outer diameter surface 112 sized to fill the space between the inserts 106, mating with an inner diameter surface 114 a, 114 b of the respective inserts 106. The plug 110 has a top journal 118 that is rotatable within a retaining nut 120. A packing 122 seals against the journal 118 to contain the pressurized fluid inside the valve 100 while permitting an external force to rotate the journal 118 and, in turn, the plug 110. In these illustrative embodiments a handle 124 is connected to the journal 118 to permit a user to manually rotate the plug 110. In alternative embodiments not depicted the journal 118 can be rotated by a powered actuator. The plug 110 also has a bottom journal 126 that rotates within the body 102 and is sealed by packing 128.

The body 102 also forms openings 116 a, 116 b intersecting the bore 104, typically referred to as an inlet and an outlet. For illustrative purposes of this description it is a given that the fluid flows through the valve 100 from left to right, or into the opening 116 a and out of the opening 116 b. However, in practice either opening 116 can provide the inlet and the other opening 116 the outlet.

Each insert 106 forms a respective opening 130 a, 130 b, and the inserts 106 are mounted in the valve 100 so that the insert openings 130 are aligned with the respective valve body opening 116. The plug 110 forms a through-opening 132 permitting a user to selectively align the opening 132 with the openings 116. FIG. 1 depicts the closed position of the valve 100, where the plug 110 is rotated so that the through-opening 132 is misaligned with the openings 116.

Namely, in the closed position of the valve 100 depicted in FIG. 1, pressurized fluid connected to the opening 116 a (inlet) impacts against the closed plug 110, sealing the backside of the plug in a metal-to-metal seal against the insert 106 b and also sealing between a seal 140 mounted in the insert 106 b between it and the valve body bore 104. Thus, in the closed position the pressurized fluid is blocked from flowing through the valve 100. By rotating the plug 110 to the open position (not depicted), its through-opening 132 comes into alignment with the openings 116, permitting the pressurized fluid to flow through the valve 100 via a flow passage established collectively by the valve body openings 116, the insert openings 130, and the valve plug through-opening 132.

FIG. 2 is similar to FIG. 1 but depicting a top entry plug valve 100′ that is constructed in accordance with other previously attempted solutions. The plug valve 100′ has inserts 106 a′, 106 b′ that are formed as segments of an open hollow cylinder instead of the inserts 106 a, 106 b in FIG. 1 that are segments of an open hollow cone. In other words, the conical surfaces in FIG. 1 are replaced here with cylindrical surfaces. For purposes of this description the skilled artisan understands that the details of construction and use of this technology applies equivalently to both types of these valves, as well as other types of valves that are used to control highly pressurized fluid. Thus, the skilled artisan understands the scope of the claims from this description's comparison to the details of construction for just one of the previously attempted solutions.

Continuing with the previously started description in comparison to the previously attempted solutions depicted in FIG. 1, FIG. 3 is an enlarged portion of it more particularly depicting how the high pressure fluid is contained inside the valve 100 in part by the seal 140 that is compressed between the outer conical surface 108 b of the insert 106 b and the valve body bore 104.

The insert 106 b has a surface 139 defining a recess 144 intersecting the outer conical surface 108 b. The term “intersecting” for purposes of this description and meaning of the claims means that the recess 144 forms a gap in the outer surface 108 b of the insert 106 b. That intersecting construction of the recess 144 with the surface 108 b permits mounting a fixed end 141 of the seal 140 in the recess 144, and sizing the seal 140 so that a distal end 143 extends from the recess 144 beyond the outer conical surface 108 b in order to seal against the valve body bore 104. Importantly, this requires the bore 104 to define a sealing surface against which the seal 140 in the insert 106 b presses against to effect the sealed engagement of the insert 106 b against the bore 104. Corrosive and/or abrasive fluid can become trapped between the seal 140 (mounted in the insert 106 b) and the bore 104 causing erosion of the bore 104. The seal 140 in these embodiments is referred to as an axial seal because the compressive forces from the surface 108 b on one side and the bore 104 on the other side act in an axial direction relative to the annular seal 140.

Although the embodiments of FIG. 3 depict only one annular seal 140 surrounding the outlet 116 b, the previously attempted solutions are not so limited. The skilled artisan understands that in alternative constructions more than one seal can be used to provide redundancy. The seal 140 can be an elastomeric seal, and in other embodiments other kinds of seals can be used such as metal seals, spring seals, and the like.

To enclose the valve plug 110 and support the journal 118, a retaining nut 120 is threaded to the valve body 102. The retaining nut 120 seals to the valve body bore 104 by another seal 146. Similar to the insert 106 b, the retaining nut 120 has a surface 147 defining a recess (sometimes referred to as a “gland”) 148 intersecting an outer diameter surface 121 of the retaining nut 120. The seal 146 is supported in the recess 148 and is sized to extend beyond the outer surface 121 to seal against a sealing surface formed by the valve body bore 104. The seal 146 in these embodiments is referred to as a radial seal because the compressive forces from the cap's surface 121 on one side and the bore 104 on the other side act in a radial direction relative to the annular seal 146. Although a radial seal is depicted, in alternative embodiments an axial seal or a crush seal and the like can be used instead of or in addition to the radial seal.

In comparison, FIG. 4 is similar to FIG. 3 but depicts a portion of a valve 150 that is constructed in accordance with embodiments of this technology. Here an insert 151 is similar in some respects but does not have a seal mounted to it like the insert 106 b (FIG. 3). Particularly, the insert 151 has an outer conical segment surface 153 that does not form a recess for mounting a seal. There is no gap in the surface 153 where a recess intersects for mounting a seal. Instead, a valve body 152 defines a valve body bore 154, and also has a surface 155 defining a recess 156 intersecting the bore 154. Again, the term “intersecting” for purposes of this description and meaning of the claims means that the recess 156 includes a gap in the bore 154. Particularly, a fixed end 157 of a seal 158 is mounted in the recess 156, and because the recess 156 intersects the bore 154, the seal 158 can be sized to extend from the recess 156 beyond the bore 154 so that a distal end 159 of the seal 158 seals against a sealing surface formed by the insert 151. Corrosive and/or abrasive fluid can become trapped between the seal 158 (mounted to the body 152) and the insert 151 causing erosion of the outer cylindrical surface of the insert 151. Importantly, in comparison to the previously attempted solutions, the construction of FIG. 4 advantageously transfers the erosion wear from the bore 154 (of the body 152) to the insert 151. When erosion has progressed to the extent that leakage occurs, repairing or replacing the insert 151 is significantly less complex and less expensive than repairing the body 152.

The body 152 also has a surface 161 forming another recess 160 that intersects the valve body bore 154. A seal 162 is mounted to the body 152 in the recess 160. Again, because of the intersecting construction of the recess 160 and the bore 154, the seal 162 can be sized to extend beyond the bore 154 to seal against a sealing surface formed by a retaining nut 164. Unlike the retaining nut 120 in FIG. 3, retaining nut 164 does not have a seal mounted to it. Instead, the seal 162 is mounted to the valve body 152 and is sized to extend from the recess 160 to seal against the outer diameter surface 166 of the retaining nut 164. In the same way as described above, this technology transfers the erosion wear away from the body 152 to the less complex and less expensive mating component, this case the retaining nut 164.

FIG. 5 is a simplified depiction of the valve 150 that is constructed in accordance with the present technology. The skilled artisan understands that variations in construction are encompassed within the contemplated embodiments of this technology that are represented in the illustrative embodiments. For example, FIG. 6 depicts another valve 170 that is constructed in accordance with this technology because each of the seals 172, 174, 176 are mounted in respective recesses formed in the valve body 184 and intersecting the valve body bore 178. The seals 172, 174, 176 are configured to extend away from the respective recesses to seal against sealing surfaces of the inserts 180 and the retaining nut 182, correspondingly. Unlike the previously attempted solutions, this construction eliminates the erosion caused by mounting a seal to a mating component that seals against the valve body bore 178.

FIG. 7 is an isometric depiction of the insert 106 in the previous valve design depicted in FIG. 1. In these embodiments the insert 106 defines slots 170 intersecting the outer conical surface 108 of the insert 106. A spring 172 is mounted to the insert 106 in each slot 170 and extends from the slot 170 to contact the valve body bore 104 (FIG. 1). As described above, that construction of the previously attempted solutions, by design, makes the valve body bore 104 the sacrificial member for any erosion caused by the springs 172.

FIG. 8 depicts a portion of the valve 150 (of this technology) in FIG. 5, but at a different cross section that passes through a recess 170′ defined by a surface 190 formed by the valve body 152′. The recess 170′ intersects the valve body bore 154′ so that a spring 172′ can be mounted in the recess 170′ at a fixed end and sized to extend from the recess 170′ to pressingly engage against an outer conical surface 108′ of the insert 106′. Like described above, this technology transfers the wear from the valve body bore 154′ to the less complex and less expensive insert 106′.

Returning momentarily to FIG. 5 that depicts the plug valve 150 constructed in accordance with embodiments of this technology. The skilled artisan having read this description understands that this technology transfers the erosion wear from the bore of the body 152 to the outer conical surface of the insert 151. As described, leakage can occur because the free end of the seal 158 abrades away the outer conical surface of the insert 151. In some illustrative embodiments the repair procedure can entail resurfacing the insert 151 to provide a new sealing surface for the seal 158 mounted in the body 152. Alternatively, the insert 151 can simply be replaced with a new one.

In yet other alternative embodiments a disposable wear member can be provided between the outer conical surface of the insert 151 and the bore of the body 152. For purposes of this description and the claims the disposable wear member can be a disposable liner (not depicted) with one surface facing the bore of the body 152 to function effectively the same as the outer conical surface of the insert 151. In some embodiments an opposing inner surface of the liner can mate directly to the outer conical surface of the insert 151. Alternatively, a seal can be provided between the inner surface of the liner and the outer conical surface of the insert. That seal can be mounted to the insert and extending to seal against a sealing surface formed by the liner (such as by using the insert 106 in FIG. 1), or the seal can be mounted to the inner surface of the liner and extending to seal against a sealing surface formed by the outer surface of the insert.

Summarizing, this technology contemplates a high pressure fluid flow apparatus constructed of a body defining a flow passage, a closure mounted to the body, and a means for sealing between the body and the closure. For purposes of this description and meaning of the claims the term “closure” means a component that is attached or otherwise joined to the body to provide a high-pressure fluid seal between the body and the closure. In some embodiments such as the described valve embodiments “closure” encompasses a moving component that is selectively positionable to control the fluid flow through the valve, such as the plug described and other components such as but not limited to a wedge, a clapper, a ball, a segment, and the like. The term “means for sealing” means the described structures and structural equivalents thereof that mount a seal to a body instead of a mating closure to transfer the wear in comparison to previously attempted solutions from the body to the closure. “Means for sealing” expressly does not encompass previously attempted solutions that mount a seal to the closure to extend therefrom and seal against the body.

The various features and alternative details of construction of the apparatuses described herein for the practice of the present technology will readily occur to the skilled artisan in view of the foregoing discussion, and it is to be understood that even though numerous characteristics and advantages of various embodiments of the present technology have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the technology, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present technology to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. An apparatus, comprising: an insert element configured to be installed within an internal chamber of a body of a valve, the body having a flow passage extending therethrough and intersecting the internal chamber; in which the chamber has a surface that joins the flow passage and has a groove formed therein, the groove surrounding the flow passage and extending along a non-planar path; in which the insert element is configured to at least partially surround a rotatable plug positioned within the body and having a fluid passage extending therethrough; in which the insert element has a fluid opening extending therethrough; and in which the insert element has a non-planar outer surface configured to engage a seal installed within the groove.
 2. A kit, comprising: a plurality of the apparatus of claim
 1. 3. The apparatus of claim 1, in which the insert element is characterized by a curved inner surface.
 4. The apparatus of claim 1, in which the surface of the chamber is complementary to a portion of the curved side of a cone.
 5. The apparatus of claim 1, in which an inner surface of the insert element is configured to mate with an outer surface of the rotatable plug.
 6. The apparatus of claim 1, in which the rotatable plug is movable between an open position that permits flow of fluid through the camber, and a closed position that blocks flow of fluid through the chamber.
 7. The apparatus of claim 6, in which the insert element is configured to be in a sealing engagement with the rotatable plug when the rotatable plug is in the closed position.
 8. The apparatus of claim 1, in which the fluid opening of the insert element has one end opening at a concave inner surface, and an opposed end opening at the non-planar outer surface and is fully enclosed between the ends.
 9. The apparatus of claim 1, in which the non-planar outer surface of the insert element is congruent with a portion of the curved side of a cone.
 10. A kit, comprising: a single-piece valve body characterized by: a flow passage that traverses the valve body along a flow path; a central chamber that interrupts the flow passage within the valve body and has one or more surfaces that join the flow passage; and a first and second endless groove situated in spaced relationship along the flow path, each groove formed in one of the one or more surfaces and extending along a non-planar path around the flow passage; and a rotatable plug configured to be positioned within the chamber and having a fluid passage extending therethrough and alignable within the flow passage; an insert element configured to be positioned within the chamber so that the insert element at least partially surrounds the rotatable plug; and a first seal configured to be disposed within the first groove.
 11. The kit of claim 10, in which the surface of the chamber is complementary to a portion of the curved side of a cone.
 12. The kit of claim 10, in which the insert element is characterized as a first insert element, the kit further comprising: a second insert element configured to be positioned within the chamber so that the insert element at least partially surrounds the rotatable plug; and a second seal configured to be disposed within the second groove.
 13. The kit of claim 12, in which the first and second insert elements each have a fluid opening extending therethrough.
 14. The kit of claim 13, in which the rotatable plug is movable between an open position that permits flow of fluid through the chamber, and a closed position that blocks fluid flow through the chamber, when the rotatable plug is installed within the single-piece body.
 15. The kit of claim 10, in which the insert element has a non-planar outer surface that is congruent with a portion of the curved side of a cone and is configured to engage the first seal.
 16. A method of assembling a valve, the valve comprising a body comprising a flow passage extending therethrough, the flow passage intersected by a chamber, the chamber having a surface that joins the flow passage, the surface having a groove formed therein, the groove surrounding the flow passage and extending along a non-planar path, the method comprising: installing an insert element within the chamber of the body of the valve such that the insert element at least partially surrounds a rotatable plug installed within the body and such that a non-planar outer surface of the insert element engages a seal installed within the groove.
 17. The method of claim 16, in which the insert element is characterized as a first insert element, the seal is characterized as a first seal, and the groove is characterized as the first groove; in which the surface of the chamber has a second groove formed therein, the second groove surrounding the flow passage and extending along a non-planar path, the method further comprising: installing a second insert element within the chamber of the body of the valve such that the second insert element at least partially surrounds a rotatable plug installed within the body and such that a non-planar surface of the second insert element engages a second seal installed within the second groove.
 18. The method of claim 16, further comprising: removing the insert element from the chamber of the body; and installing a new insert element within the chamber of the body of the valve such that the new insert element at least partially surrounds the rotatable plug installed within the body and such that a non-planar surface of the new insert element engages the seal installed within the groove.
 19. The method of claim 16, further comprising: removing the insert element from the chamber of the body; removing the seal from the groove; and installing a new seal within the groove.
 20. The method of claim 19, further comprising: installing a new insert element within the chamber of the body of the valve such that the new insert element at least partially surrounds the rotatable plug installed within the body and such that a non-planar surface of the new insert element engages the new seal installed within the groove. 